Surgical stapling device with replaceable staple cartridge

ABSTRACT

A surgical stapling device includes an anvil and a staple cartridge. The staple cartridge includes structure to prevent the staple cartridge from being inserted into a channel member that is not sized to receive the staple cartridge. The staple cartridge and the channel member are configured to minimize risk of loading the wrong size staple cartridge into the surgical stapling device.

FIELD

This technology is generally related to surgical stapling devices and,more particularly, to surgical stapling devices with replaceable staplecartridges.

BACKGROUND

Surgical stapling devices for endoscopic use are well known and commonlyused to minimize patient trauma and reduce patient recovery times.Typically, endoscopic stapling devices include a tool assembly that hasan anvil assembly and a cartridge assembly that are coupled to eachother by a pivot member and movable in relation to each other betweenopen and clamped positions. The cartridge assembly includes a channelmember that supports a staple cartridge. The channel member of the toolassembly is dimensioned to receive a staple cartridge of a particularsize or length, e.g., 30 mm, 45 mm, 60 mm, etc.

In order to facilitate reuse of the surgical stapling device, the staplecartridge of the tool assembly may be replaceable. In some such devices,replacement of the staple cartridge deactivates a lock out assembly thatprevents firing of the surgical stapling device if the staple cartridgeis spent, i.e., has already been fired. Serious complications can resultif the wrong size staple cartridge is loaded onto the surgical staplingdevice.

A continuing need exists in the art for an endoscopic surgical staplingdevice that minimizes a risk of loading an improperly sized staplecartridge into a channel member of the stapling device.

SUMMARY

Aspects of this disclosure are directed to tool assembly including ananvil and a cartridge assembly. The anvil has a proximal portion and adistal portion. The cartridge assembly is movably supported in relationto the anvil between open and clamped positions. The cartridge assemblyincludes a channel member and a staple cartridge. The channel member hasa base wall and side walls that define an open cavity. The side wallshave a first end coupled to the base wall and a second end includingcutouts. At least one of the side walls has an inner surface defining aplacement recess. The staple cartridge has a cartridge body that definesa central knife slot and a plurality of staple pockets positioned oneach side of the central knife slot. The staple cartridge includes sidewalls. Each of the side walls of the staple cartridge includesprotrusions and a placement rib. The protrusions are received within thecutouts of the channel member to secure the staple cartridge within theopen cavity of the channel member and the placement rib is receivedwithin the placement recess.

Other aspects of the disclosure are directed to a surgical staplingdevice including a handle assembly, an elongate body, and a toolassembly. The handle assembly includes a stationary handle and atrigger. The elongate body has a proximal portion and a distal portion.The proximal portion is supported on the handle assembly. The toolassembly is supported on the distal portion of the elongate body andincludes an anvil and a cartridge assembly. The cartridge assembly ismovably supported in relation to the anvil between open and clampedpositions and includes a channel member and a staple cartridge. Thechannel member has a base wall and side walls that define an opencavity. The side walls of the channel member have a first end coupled tothe base wall and a second end that has cutouts. At least one of theside walls of the channel member has an inner surface defining aplacement recess. The staple cartridge has a cartridge body that definesa central knife slot and a plurality of staple pockets positioned oneach side of the central knife slot. The staple cartridge includes sidewalls that include protrusions and a placement rib. The protrusions arereceived within the cutouts of the channel member to secure the staplecartridge within the open cavity of the channel member and the placementrib is received within the placement recess.

In aspects of the disclosure, the cartridge body includes an angled wallthat defines a distal end of the placement recess.

In some aspects of the disclosure, the placement rib includes an angleddistal surface that engages the angled wall of the cartridge body whenthe staple cartridge is inserted into the open cavity of the channelmember to move the cartridge body proximally within the open cavity.

In certain aspects of the disclosure, the angled wall slopes upwardlytowards the anvil in a distal direction.

In aspects of the disclosure, the tool assembly includes a driveassembly that has a flexible beam and a working end, and the driveassembly is movable from a retracted position to an advanced positionthrough the anvil and the cartridge assembly to actuate the toolassembly.

In some aspects of the disclosure, the working end of the drive assemblyincludes a clamping member that has a first beam, a second beam, and avertical strut connecting the first beam to the second beam.

In certain aspects of the disclosure, an actuation sled is positionedwithin the cartridge body distally of the working end of the driveassembly, and the actuation sled is movable within the cartridge bodyfrom a retracted position to an advanced position in response tomovement of the drive assembly from its retracted position to itsadvanced position.

In aspects of the disclosure, the tool assembly includes a lockingmember that is movable from a locked position to an unlocked position,wherein in the locked position, the locking member obstructs movement ofthe drive assembly from its retracted position to its advanced position.

In some aspects of the disclosure, the actuation sled retains thelocking member in its unlocked position when the actuation sled is inits retracted position.

In certain aspects of the disclosure, the locking member is biased tothe locked position.

Other features of the disclosure will be appreciated from the followingdescription.

BRIEF DESCRIPTION OF DRAWINGS

Various aspects of the disclosure are described herein below withreference to the drawings, wherein:

FIG. 1 is a side perspective view of a surgical stapling deviceincluding a 60 mm tool assembly supporting a 60 mm cartridge assemblyaccording to aspects of the disclosure;

FIG. 2 is an enlarged view of the indicated area of detail shown in FIG.1 ;

FIG. 3 is a side perspective view of the tool assembly of the surgicalstapling device shown in FIG. 1 with a cartridge assembly separated froma channel member of the tool assembly;

FIG. 4 is a side perspective exploded view of a cartridge assembly anddrive assembly of the surgical stapling device shown in FIG. 1 ;

FIG. 5 is a cross-sectional view taken an axis transverse to alongitudinal axis of the tool assembly shown in FIG. 2 with the toolassembly in an open position;

FIG. 6 is a cross-sectional view of taken along section line 6-6 of FIG.2 ;

FIG. 7 is a side perspective view of a 45 mm tool assembly with the 60mm cartridge assembly;

FIG. 8 is a side view of the 45 mm tool assembly and the 60 mm staplecartridge as the 60 mm cartridge assembly is inserted into the 45 mmtool assembly;

FIG. 9 is a cross-sectional view taken along section line 9-9 of FIG. 8; and

FIG. 10 is a cross-sectional view taken along the longitudinal axis ofthe tool assembly as the 60 mm cartridge assembly is inserted into the45 mm tool assembly.

DETAILED DESCRIPTION

The disclosed surgical stapling device will now be described in detailwith reference to the drawings in which like reference numeralsdesignate identical or corresponding elements in each of the severalviews. However, it is to be understood that the aspects of thedisclosure are merely exemplary of the disclosure and may be embodied invarious forms. Well-known functions or constructions are not describedin detail to avoid obscuring the disclosure in unnecessary detail.Therefore, specific structural and functional details disclosed hereinare not to be interpreted as limiting, but merely as a basis for theclaims and as a representative basis for teaching one skilled in the artto variously employ the disclosure in virtually any appropriatelydetailed structure. In addition, directional terms such as front, rear,upper, lower, top, bottom, distal, proximal, and similar terms are usedto assist in understanding the description and are not intended to limitthe disclosure.

In this description, the term “proximal” is used generally to refer tothat portion of the device that is closer to a clinician, while the term“distal” is used generally to refer to that portion of the device thatis farther from the clinician. In addition, the term “endoscopic” isused generally used to refer to endoscopic, laparoscopic, arthroscopic,and/or any other procedure conducted through a small diameter incisionor cannula. Further, the term “clinician” is used generally to refer tomedical personnel including doctors, nurses, and support personnel.

This disclosure is directed to a tool assembly that includes an anviland a cartridge assembly. The cartridge assembly includes a channelmember of a first size and a replaceable staple cartridge of a firstsize. The channel member of the first size defines a placement recessand the staple cartridge of the first size includes a placement rib. Theplacement rib is received within the placement recess to allow thestaple cartridge of the first size to be received within the channelmember of the first size. Different size channel members do not includeplacement recesses to prevent placement of staple cartridges of thefirst size from being inserted into the channel member of the firstsize.

FIG. 1 illustrates exemplary aspects of the disclosed surgical staplingdevice shown generally as stapling device 10. The stapling device 10includes a handle assembly 12, an elongate body 14 defining alongitudinal axis “X”, and a tool assembly 16 of a first size, e.g. 60mm. The handle assembly 12 includes a stationary handle 18 and a trigger20 that is movable in relation to the stationary handle 18 to actuatethe tool assembly 16. In aspects of the disclosure, the stapling device10 includes a rotation knob 22 and an articulation lever 24. Therotation knob 22 is coupled to the handle assembly 12 and supports theelongate body 14 to facilitate rotation of the elongate body 14 and toolassembly 16 in relation to the handle assembly 12 about the longitudinalaxis “X”. The articulation lever 24 is coupled to the tool assembly 16to articulate the tool assembly 16 from a position aligned with thelongitudinal axis “X” to positions defining acute angles with thelongitudinal axis “X”. In some aspects of the stapling device 10, thehandle assembly 12 includes retraction knobs 26 for retracting a driveassembly of the stapling device 10. For a more detailed description ofexemplary aspects of the handle assembly 12 of the stapling device 10,see, e.g., U.S. Pat. No. 6,241,139 (“the ‘139 Patent”). Although thehandle assembly 12 is illustrated as a manually operated handleassembly, it is envisioned that the handle assembly 12 could be apowered handle assembly such as described in U.S. Pat. No. 9,055,943.

FIGS. 2 and 3 illustrate the tool assembly 16 of the stapling device 10(FIG. 1 ). The tool assembly 16 includes an anvil 28 and a cartridgeassembly 30 that are movable in relation to each other between an openposition (FIG. 2 ) and a clamped position. In aspects of the disclosure,the anvil 28 and the cartridge assembly 30 are coupled together withpivot members 32 such that the cartridge assembly 32 can pivot inrelation to the anvil 30 between an open position (FIG. 1 ) and aclamped position (FIG. 8 ). Although the cartridge assembly 30 isillustrated as pivoting towards a stationary anvil 28, it is envisionedthat the anvil 30 could be adapted to pivot towards a stationarycartridge assembly 30.

The cartridge assembly 30 includes a channel member 34 and a staplecartridge 36. The channel member 34 includes a base wall 38 and spacedside walls 40 that define an open cavity 42 (FIG. 3 ). The staplecartridge 36 is releasably received within the open cavity 42 and can bereplaced after each firing of the stapling device 10 to facilitate reuseof the stapling device 10 (FIG. 1 ). The channel member 34 isdimensioned to receive a staple cartridge 36 of a specific size. Forexample, in the tool assembly 16, the channel member 34 is dimensionedto receive a staple cartridge 36 having a size that corresponds to thesize of the channel member 34, e.g., 30 mm, 45 mm, 60 mm etc. Similarly,the anvil 28 of the tool assembly 16 is dimensioned to be used with astaple cartridge 36 of a specific size, e.g., 60 mm.

FIGS. 4-6 illustrate the tool assembly 16 of the first size, e.g., 60mm, which includes the cartridge assembly 30, a drive assembly 50, anactuation sled 52, and a lockout member 54. The drive assembly 50includes a flexible drive beam 60 and a working end 62. The flexibledrive beam 60 has a proximal portion 64 and a distal portion 66 thatsupports the working end 62 of the drive assembly 50. The distal portion66 of the flexible drive beam 60 defines a stop surface 66 a (FIG. 4 ).In aspects of the disclosure, the working end of the drive assembly 50includes a clamping member in the form of an I-beam that includes afirst beam 70, a second beam 72, and a vertical strut 74 thatinterconnects the first beam 70 to the second beam 72. In aspects of thedisclosure, the vertical strut 74 includes a cutting edge of knife 76.The proximal portion 64 of the flexible drive beam 60 is coupled to adrive member (not shown) that is supported within the elongate body 14(FIG. 1 ) of the surgical stapling device 10. The drive member (notshown) is movable to move the drive assembly 50 in relation to the anvil28 and cartridge assembly 30 between retracted and advanced positions.

The actuation sled 52 is supported within the staple cartridge 36 formovement between a retracted position (FIG. 6 ) and an advanced positionand includes a plurality of angled camming surfaces 78. The angledcamming surfaces 78 are positioned to engage pushers 79 (FIG. 6 )supported within the staple cartridge 36 to drive staples from thestaple cartridge 36. The actuation sled 52 is positioned distally of theworking end 68 of the drive assembly 50 within the staple cartridge 36and is engaged by the working end 68 when the drive assembly 50 is movedfrom its retracted position towards its advanced position to move theactuation sled 52 from its retracted position to its advanced position.

The locking member 54 includes a body 80 having centrally located pivotmembers 82 (only one is shown), a pair of downwardly extending distallegs 84, and a proximally located stop member 86. The locking member 86is pivotable about the pivot members 82 from a first unlocked position(FIG. 6 ) in which the stop member 86 is positioned below the stopsurface 66 a on the distal portion 66 of the flexible drive beam 60 to alocked position in which the stop surface 66 a is aligned with the stopsurface 66 a on the distal portion 66 of the flexible drive beam 60 ofthe drive assembly 50. In the locked position, the locking member 54blocks movement of the drive assembly 50 towards its advanced position.The locking member 86 is biased towards the locked position by a biasingmember 87 (FIG. 10 ). When the actuation sled 52 is in its retractedposition, the distal legs 84 of the locking member 54 are engaged withthe actuation sled 52 to retain the locking member 54 in the unlockedposition. U.S. Pat. No. 9,757,126 describes in detail the constructionand operation of the locking member 54 and the actuation sled 52.

The staple cartridge 36 of the first size includes a cartridge body 100that defines a central knife slot 102 and a plurality of staple pockets104 positioned on each side of the central knife slot 102. In aspects ofthe disclosure, the staple pockets 104 are aligned in rows on each sideof the central knife slot 102. Although three rows of staple pockets 104are illustrated on each side of the central knife slot 102, it isenvisioned that the staple cartridge 36 can include one or more rows ofstaple pockets 104. The cartridge body 100 also includes side walls 106(only one is shown) that include one or more projections 108. Each ofthe side walls 106 includes an overhang or shoulder 107 that ispositioned to rest atop the side walls 40 of the channel 34 when thestaple cartridge 36 is inserted into the open cavity 42 of the channelmember 34. In aspects of the disclosure, the one or more of theprojections 108 can have an outer ribbed surface 110 (FIG. 4 ) toprovide a gripping surface to facilitate removal of the staple cartridge36 from the channel member 34. The side walls 106 can also include aprotrusion 106 a that is received within openings 109 a of a cartridgepan 109 to retain the cartridge pan 109 on the cartridge body 100. Thecartridge pan 109, as known in the art, is secured to the cartridge bodyto retain the pushers 79 (FIG. 6 ) and staples (not shown) within thecartridge body 100. At least one of the side walls 106 of the cartridgebody 100 includes a placement rib 112. In aspects of the disclosure, theplacement rib 112 projects outwardly from the at least one side wall 106and includes an angled distal surface 114. In certain aspects of thedisclosure, each of the side walls 106 of the cartridge body 100includes a placement rib 112.

As described above, the channel member 34 of the tool assembly 16includes the base wall 38 and the side walls 40 which define the opencavity 42. The side walls 40 include cutouts 120 (FIG. 4 ) that receivethe projections 108 of the staple cartridge 36 to secure the staplecartridge 36 within the open cavity 42 of the channel member 36. Theresilient wall portion 106 a of the staple cartridge 36 is biasedinwardly by an inner surface of the side walls 40 of the channel member34 when the staple cartridge 36 is inserted into the open cavity 42 ofthe channel member 34 to assist in retaining the staple cartridge 36within the channel member 42.

The side walls 40 of the channel member 34 of the tool assembly 16 ofthe first size, e.g., 60 mm, includes placement recesses 128 that arepositioned to receive the placement ribs 112 of the staple cartridge 36.In aspects of the disclosure, the placement recesses 128 are defined inpart by an angled distal wall 130 (FIG. 4 ) that slopes upwardly towardsthe anvil 28 in a distal direction. As described below, only the channelmember 34 of the tool assembly 16 of the first size includes theplacement recesses 128. When a staple cartridge 36 of the first size isinserted into the channel member 34 of the first size, the placementribs 112 are received within the placement recesses 128 to allow thestaple cartridge 36 to be received within the open cavity 42 of thechannel member 34 such that the shoulders 107 on the side walls 106 ofthe staple cartridge rest atop the side walls 40 of the channel member34. When the staple cartridge 36 is inserted into the channel member 34,the angled distal wall 130 defining the placement recess 128 engages theangled distal surface 114 of the placement rib 112 to urge the staplecartridge proximally within the open cavity 42 of the channel member 34to move the actuation sled 52 (FIG. 4 ) into engagement with the lockingmember 54 (FIG. 6 ) to pivot the locking member 54 in the directionindicated by arrows “A” in FIG. 6 to its unlocked position.

FIGS. 7-10 illustrate the staple cartridge 36 of the first size as thestaple cartridge 36 is inserted into a channel member 234 of a toolassembly 216 of a different size, e.g., 45 mm. The channel member 234 ofthe tool assembly 216 of the second size is substantially identical tothe channel member 34 of the tool assembly 16 of the first size exceptthat the channel member 234 does not include placement recesses. Assuch, when the staple cartridge 36 of the first size is inserted intothe channel member 234 of the second size, the placement ribs 112 on thestaple cartridge 36 engage upper surfaces 240 a of the side walls 240 ofthe channel member 234 of the tool assembly 216 to prevent the staplecartridge 36 from being properly seated within the cavity 242 of thechannel member 234. As illustrated in FIG. 10 , since the staplecartridge 36 cannot properly seat within the cavity 242 of the channelmember 234 of the tool assembly 216, the actuation sled 254 of the toolassembly 216 cannot engage the locking member 252 and the locking member252 remains in the unlocked position. As such, the stapling device 10(FIG. 1 ) cannot be fired.

The above-described staple cartridge 36 of a first size and channelmember 34 of the first size allow the staple cartridge 36 to only beseated within a properly sized channel member 34 and prevents insertionof the staple cartridge 36 of the first size into a channel member 234of the second size. For example, if the staple cartridge 36 of the firstsize is a 60 mm staple cartridge and the channel member 234 of a secondsize is dimensioned to receive a 45 mm staple cartridge, the placementribs 112 will engage the side walls 240 of the channel member 234 as aclinician attempts to insert the staple cartridge 36 into the opencavity 242 of the channel member 234 to prevent the staple cartridge 36from being properly seated within the cavity 242.

Although the first size is described herein as being a 60 mm staplecartridge or tool assembly and the second size is described as being a45 mm staple cartridge or tool assembly, it is envisioned that theaspects of this disclosure could be incorporated into a variety ofdifferent size staple cartridges and tool assemblies.

Persons skilled in the art will understand that the devices and methodsspecifically described herein and illustrated in the accompanyingdrawings are non-limiting exemplary aspects of the disclosure. It isenvisioned that the elements and features illustrated or described inconnection with one exemplary aspect of the disclosure may be combinedwith the elements and features of another without departing from thescope of the disclosure. As well, one skilled in the art will appreciatefurther features and advantages of the disclosure based on theabove-described aspects of the disclosure. Accordingly, the disclosureis not to be limited by what has been particularly shown and described,except as indicated by the appended claims.

What is claimed is:
 1. A tool assembly comprising: an anvil; and acartridge assembly movably supported in relation to the anvil betweenopen and clamped positions, the cartridge assembly including: a channelmember having a base wall and side walls that define an open cavity, theside walls of the channel member having a first end coupled to the basewall and a second end including cutouts, at least one of the side wallsof the channel member having an inner surface defining a placementrecess; and a staple cartridge having a cartridge body defining acentral knife slot and a plurality of staple pockets positioned on eachside of the central knife slot, the staple cartridge including sidewalls, each of the side walls of the staple cartridge includingprotrusions and a placement rib, wherein the protrusions are receivedwithin the cutouts of the channel member to secure the staple cartridgewithin the open cavity of the channel member and the placement rib isreceived within the placement recess.
 2. The tool assembly of claim 1,wherein the cartridge body includes an angled wall that defines a distalend of the placement recess.
 3. The tool assembly of claim 2, whereinthe placement rib includes an angled distal surface that engages theangled wall of the cartridge body when the staple cartridge is insertedinto the open cavity of the channel member to move the cartridge bodyproximally within the open cavity.
 4. The tool assembly of claim 2,wherein the angled wall slopes upwardly towards the anvil in a distaldirection.
 5. The tool assembly of claim 1, further including a driveassembly having a flexible beam and a working end, the drive assemblymovable from a retracted position to an advanced position through theanvil and the cartridge assembly to actuate the tool assembly.
 6. Thetool assembly of claim 5, wherein the working end of the drive assemblyincludes a clamping member having a first beam, a second beam, and avertical strut connecting the first beam to the second beam.
 7. The toolassembly of claim 6, further including an actuation sled positionedwithin the cartridge body distally of the working end of the driveassembly, wherein the actuation sled is movable within the cartridgebody from a retracted position to an advanced position in response tomovement of the drive assembly from its retracted position to itsadvanced position.
 8. The tool assembly of claim 7, further including alocking member that is movable from a locked position to an unlockedposition, wherein in the locked position, the locking member obstructsmovement of the drive assembly from its retracted position to itsadvanced position.
 9. The tool assembly of claim 8, wherein theactuation sled is positioned to retain the locking member in itsunlocked position when the actuation sled is in its retracted position.10. The tool assembly of claim 9, wherein the locking member is biasedto the locked position.
 11. A surgical stapling device comprising: ahandle assembly including a stationary handle and a trigger; an elongatebody having a proximal portion and a distal portion, the proximalportion supported on the handle assembly; and a tool assembly supportedon the distal portion of the elongate body, the tool assembly including:an anvil; and a cartridge assembly movably supported in relation to theanvil between open and clamped positions, the cartridge assemblyincluding: a channel member having a base wall and side walls thatdefine an open cavity, the side walls of the channel member having afirst end coupled to the base wall and a second end including cutouts,at least one of the side walls of the channel member having an innersurface defining a placement recess; and a staple cartridge having acartridge body defining a central knife slot and a plurality of staplepockets positioned on each side of the central knife slot, the staplecartridge including side walls, each of the side walls of the staplecartridge including protrusions and a placement rib, wherein theprotrusions are received within the cutouts of the channel member tosecure the staple cartridge within the open cavity of the channel memberand the placement rib is received within the placement recess.
 12. Thesurgical stapling device of claim 11, wherein the cartridge bodyincludes an angled wall that defines a distal end of the placementrecess.
 13. The surgical stapling device of claim 12, wherein theplacement rib includes an angled distal surface that engages the angledwall of the cartridge body when the staple cartridge is inserted intothe open cavity of the channel member to move the cartridge bodyproximally within the open cavity.
 14. The surgical stapling device ofclaim 12, wherein the angled wall slopes upwardly towards the anvil in adistal direction.
 15. The surgical stapling device of claim 11, whereinthe tool assembly further includes a drive assembly having a flexiblebeam and a working end, the drive assembly movable from a retractedposition to an advanced position through the anvil and the cartridgeassembly to actuate the tool assembly.
 16. The surgical stapling deviceof claim 15, wherein the working end of the drive assembly includes aclamping member having a first beam, a second beam, and a vertical strutconnecting the first beam to the second beam.
 17. The surgical staplingdevice of claim 16, wherein the tool assembly further includes anactuation sled positioned within the cartridge body distally of theworking end of the drive assembly, wherein the actuation sled is movablewithin the cartridge body from a retracted position to an advancedposition in response to movement of the drive assembly from itsretracted position to its advanced position.
 18. The surgical staplingdevice of claim 17, further including a locking member that is movablefrom a locked position to an unlocked position, wherein in the lockedposition, the locking member obstructs movement of the drive assemblyfrom its retracted position to its advanced position.
 19. The surgicalstapling device of claim 18, wherein the actuation sled is positioned toretain the locking member in its unlocked position when the actuationsled is in its retracted position.
 20. The surgical stapling device ofclaim 19, wherein the locking member is biased to the locked position.